s_sr820.pdf

500-SHEET FINISHER(Machine Code: G302/B442)

10 August, 2001 EXTERIOR

B442-1

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1. REPLACEMENT AND ADJUSTMENT1.1 EXTERIORNOTE: This manual uses several symbols. The meanings for these symbols are

as follows:☛: See or refer to !: screw ": connector #: clip

Front cover[A]: : Front cover (!1)

Rear cover[A]: Rear cover (!1)

B442R101.WMF

B442R102.WMF

[A]

[A]

EXTERIOR 10 August, 2001

B442-2

Top cover[A]: Top cover (2 links)

Front lower guide

[A]: Output tray (#2)[B]: Front lower guide (!2)

NOTE: 1) When re-attaching the lower guide, be sure that it is not in contact withthe exit lower guide and that the exit lower guide moves smoothly.

2) Make sure that the blue and black cables are in the correct position, asengraved on the inside of the front lower guide.

B442R105.WMF

B442R104.WMF

B442R116.WMF

[A]

[A]

[B]

10 August, 2001 EXTERIOR

B442-3

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Right cover[A]: Grounding plate (!1)[B]: Right cover (!2)

B442R103.WMF[A]

[B]

ENTRANCE UPPER GUIDE / PAPER EXIT UNIT 10 August, 2001

B442-4

1.2 ENTRANCE UPPER GUIDE / PAPER EXIT UNIT

• Front, rear, and top covers and front lower guide (☛ 1.1 Exterior)[A]: Entrance upper guide (!2, "1)[B]: Paddle gear spring[C]: Paddle gear (#1)[D]: Paddle gear holder[E]: Bushing (#1)[F]: Paper exit unit holder (!1)[G]: Rear paper exit unit holder (!1)[H]: Exit unit

NOTE: Keep the paper exit unit stays inthe upper position. Rotate thepaddle roller into the positionshown in the illustration [a]. Then,insert the paddle gear, makingsure that the pawl on the gear’souter frame is resting on the clutchlink [b].

B442R106.WMF

B442R107.WMF

[A]

[B]

[C]

[D]

[E]

[F]

[G]

[H]

[a]

[b]

10 August, 2001 ENTRANCE LOWER GUIDE

B442-5

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1.3 ENTRANCE LOWER GUIDE

• Entrance upper guide (☛ 1.2 Entranceupper guide / Exit unit)

• Exit unit (☛1.2 Entrance upper guide /Exit unit)

[A]: Release tension bracket (!1)[B]: Reverse roller gear bracket (!2)[C]: Timing belt[D]: Entrance lower guideNOTE: When re-assembling the tension

bracket, rotate the main motorcounter clockwise to tighten thetiming belt.

1.4 PAPER EXIT UNIT GEAR / PADDLE ROLLERSOLENOID

• Front cover (☛ 1.1 Exterior)[A]: Gear bracket (!3)[B]: Paper exit unit gear[C]: Paddle roller solenoid (!1)

B442R108.WMF

B442R109.WMF [A]

[B]

[C]

[A]

[B][C]

[D]

STAPLER UNIT 10 August, 2001

B442-6

1.5 STAPLER UNIT• Rear cover (☛1.1 Exterior)[A]: Stapler unit bracket (!2, "1)[B]: Stapler unit (!3)

1.6 JOGGER TRAY UNIT• Entrance upper guide and paper exit unit

(☛1.2 Entrance upper guide / paper exitunit)

• Entrance lower guide (☛1.2 Entrancelower guide)

• Paper exit unit gear and Paddle rollersolenoid (☛1.4 Paper exit unit gear /Paddle roller solenoid)

• Stapler unit (☛ 1.5 Stapler unit)[A]: Jogger tray unit holders (!2)[B]: Jogger tray unit (!1, "3)NOTE: Be sure to connect the black cable

to the paper exit sensor and theblue one to the jogger homeposition sensor.

B442R115.WMF

B442R110.WMF

[A]

[B]

[A]

[B]

10 August, 2001 PAPER EXIT SENSOR FEELER

B442-7

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1.7 PAPER EXIT SENSOR FEELER• Jogger tray unit (☛1.6 Jogger tray unit)• Jogger motor (☛1.9 Jogger motor)[A]: Paper exit sensor feeler

1.8 MAIN MOTOR• Right cover (☛1.1 Exterior)[A]: Release tension bracket (!1)[B]: Main motor (!2, "1)

B442R121.WMF

B442R113.WMF

[A]

[A]

[B]

JOGGER MOTOR 10 August, 2001

B442-8

1.9 JOGGER MOTOR

• Front lower guide (☛1.1 Exterior)[A]: Jogger motor (!2, "3)

1.10 CONTROL BOARD

• Front lower guide (☛1.1 Exterior)[A]: Control board (!1, "12)

B442R114.WMF

B442R112.WMF

[A]

[A]

10 August, 2001 OUTPUT TRAY UNIT

B442-9

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1.11 OUTPUT TRAY UNIT

[A]: Output tray cover (!2)[B]: Tray holder (!1)[C]: Links[D]: Connector cover[E]: Output tray motor link unit (!1)[F]: Rear cover (!1)[G]: Output tray motor ("1)

NOTE: When re-attaching the motor linkunit, the arrows on each of thegears need to face each other asshown in the illustration.

B442R117.WMF B442R118.WMF

B442R119.WMF

B442R120.WMF

[A]

[B] [C]

[D]

[E]

[F]

[G]

OVERALL MACHINE INFORMATION 10 August, 2001

B442-10

2. DETAILED DESCRIPTIONS2.1 OVERALL MACHINE INFORMATION2.1.1 COMPONENT LAYOUT

Mechanical component layout

1. Output tray2. Stack height detection lever3. Paper exit roller4. Jogger tray5. Reverse roller

6. Lower entrance guide7. Upper entrance guide8. Paper exit unit9. Paddle roller10. Lower exit guide

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1

2 3

10

4

6

7

89

5

10 August, 2001 OVERALL MACHINE INFORMATION

B442-11

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Drive layout

1. Main motor2. Exit roller timing belt3. Main motor timing belt4. Output tray motor

5. Output tray link gears6. Paper exit unit drive gear7. Reverse roller8. Paper exit roller

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2

3

1

65

4

8

7

OVERALL MACHINE INFORMATION 10 August, 2001

B442-12

2.1.2 ELECTRICAL COMPONENT DESCRIPTIONS

See the next page for the component description table.

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18

17

15

14

13

1110

12

9

7

6

5

4

32

8

1

16

10 August, 2001 OVERALL MACHINE INFORMATION

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Symbols Name Function Index No.Motors

M1 Main Drives all the rollers 6M2 Jogger Drives the jogger fence 9M3 Output Tray Drives the tray up and down 12

Stapler Drives the stapler 16

SensorsS1 Entrance Detects paper at the entrance 3S2 Exit Detects paper at the exit 15S3 Stack height Detects the top of the paper stack 13S4 Lever Detects the position of stack height lever 14

S5 Jogger homeposition

Detects the position of the jogger fence 2

S6 Top cover Detects if the top cover is open 1

S7 Tray upper limit Detects when the tray is lifted to the upperlimit 11

S8 Stack near-limit Detects when the tray is at its lowest limit(almost full) 10

SolenoidsSOL1 Exit unit gear Moves the paper exit unit up and down 7SOL2 Paddle roller Switches paddle roller rotation on and off. 5

SOL3 Stack heightlever

Moves the stack height lever into contactwith the top of the stack. 8

PCBsPCB1 Main control Controls all finisher functions 4

SwitchesSW1 Paper exit unit Switches DC for the stapler unit on and off. 18SW2 Staple unit cover Cuts DC when staple unit cover is open. 17

DETAILED SECTION DESCRIPTIONS 10 August, 2001

B442-14

2.2 DETAILED SECTION DESCRIPTIONS2.2.1 OUTPUT TRAY MECHANISM

Stack height detection

Stack height detection lever [A]: Driven by stack height lever solenoid [B].Two sensors detect the height of the stack in the output tray: the stack height [C]and lever [D] sensors.

Stack heightsensor Lever sensor Status

Off Off The stack height is below the target. The output tray islifted to the target position.

Off On Target position

On On The stack height is more the target. The output tray islowered to the target position.

On Off The stack height detection lever is at home position.

Off: Actuator not in sensor

At the start of a print job, the solenoid turns off. The stack height detection levercomes down, to detect the current stack level.When a sheet of paper is being fed out, the solenoid turns on and the lever goesback up to home position (inside the unit).After paper has been fed out, the solenoid turns on again, and the lever detects thelevel of the stack.

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[A][B]

[C]

[D]

10 August, 2001 DETAILED SECTION DESCRIPTIONS

B442-15

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Output tray up/down mechanism

OverviewThe output tray motor [A] lifts/lowers the tray if the stack height is not at the targetposition.Gears [B] and [C] keep the angle of the tray constant at any tray position.

Output Tray Downward MovementThe top of the paper stack is checked after every page (or set of pages) has beenfed out. If the top of the stack is higher than the target level, the output tray motormoves the tray down.When the stack near-limit sensor [D] detects the actuator on gear [C], a stack near-limit signal is transferred to the main frame. The tray cannot move any lower. Thenext time the top of the stack height is above the target level, printing stops.

Output Tray Upward MovementIf paper is removed from the stack, the top of the stack will be lower than the targetlevel, and the output tray motor moves the tray up.When the tray upper limit sensor [E] detects the actuator on gear [B], the traycannot be moved up any more, so the motor stops.

B442D105.WMF

[A]

[C]

[D] [E]

[B]


B442-16

2.2.2 PAPER FEED

OverviewThe following paper feed out modes can be selected at the printer driver.

Mode DescriptionStraight feed out mode Paper is fed directly to the output tray without shifting or stapling.

Shift sorting mode Alternate sets are shifted before being fed to the output tray.Stapling mode All sets are shifted and stapled, then fed to the output tray.

Straight feed out mode

Before the job, the exit unit [A] is up, and the exit unit gear solenoid [B] is on,pulling lever [C] away from the exit unit gear [D].At the start of the job, the stack height detection lever detects the top of the stack.The tray moves up or down if the top of the stack is not at the correct level.

When the paper exit sensor in the main frame turns on, the finisher main motorstarts. It drives the exit unit gear [D] through idle gear [E]. The gear pulls paper exitunit [A] down, using the paper exit link [F]. The link also moves the paper exit roller[H] up through the exit roller drive gear [G].When the motor starts, the solenoid switches off and a spring pushes lever [C] intocontact with the exit unit gear [D].When a part of the exit unit gear without threads [I] faces the idle gear, the gearstops turning (see the left-hand diagram). The lever [C] catches a peg on the exitunit gear, to make sure that it stops at the correct position. The paper exit rollers[H] now contact each other and the main motor feeds out the paper.When the last page has been fed out, the solenoid turns on to pull the lever awayfrom the gear. The gear starts turning, to lift the exit unit to the standby position.When the other part of the exit unit gear without threads [J] faces the idle gear, theexit unit gear stops. Then, the main motor stops and the solenoid turns off.

B442D109.WMFB442D106.WMF

[A]

[C][C]

[E]

[F]

[G]

[G]

[H] [I]

[B]

[J]

[D]


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Shift sorting mode

At the start of the job, and for odd numbered sets of copies, the mechanism is thesame as the straight feed out mode. However, even numbered sets are fed back tothe jogger tray, which shifts the sets to one side before feeding them out.This section describes what happens for even-numbered sets (sets 2, 4, 6 etc) ofthe job.A short time after the entrance sensor [A] detects the first page of the set, thepaper exit unit solenoid turns on to restart the rotation of the paper exit unit gear,raising the paper exit unit to the standby position. It stays there until after the lastpage of the set.The paper cannot feed out, so it drops into the jogger tray [B]. The paddle rollersolenoid [C] turns on and the paddle roller [D] feeds the paper to the reverse roller[E]. The reverse roller feeds the paper to the end fence [F] of the jogger tray.

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[A]

[E] [F]

[B]

[D]

[C]


B442-18

After the paper reaches the end fence [A], the jogger fence [B] shifts the paperacross. The jogger motor [C] drives the jogger fence. The home position sensor [D]detects when the jogger fence has returned to home position.When the next set begins, the paper exit unit moves down, and the machineoperates the same way as straight feed out mode. At this time, the entire set in thejogger tray is fed out at the same time as the first page of the next set. However,the set coming from the jogger tray has been shifted to one side.If the last set is an even-numbered set, the paper exit unit must be pulled down tofeed the final set out of the jogger tray. Then the exit unit moves back up to thestandby position.The capacity of the jogger tray is 30 sheets. If the set contains more than 30sheets, the machine feeds out the first 30 from the jogger tray, then continues withthe rest of the set, using the jogger tray.

B442D107.WMF

[B]

[A]

[C]

[D]


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Stapling mode

The stapler is attached to the jogger tray, so all sets go to the jogger tray.After all pages of a set have entered the jogger tray and been shifted across, thepaper exit link [A] pulls the paper exit unit [B] down until knob [C] on the exit unitpushes the link lever [D] for the exit unit switch [E]. This turns on the exit unitswitch. When this switch is on, dc is supplied to the stapler unit [F] and the mainmotor is turned off.The exit unit switch is activated when the exit unit is pulled part-way down. Afterstapling the set of prints, the paper exit unit is pulled down again until the unitcomes in contact with the paper exit roller [G], and the stapled set is fed out.

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[B]

[C][E]

[F]

[D]

[A]

[G]

[B]


B442-20

2.2.3 JAM CONDITIONSSensors Conditions

Remaining paper detection EntranceExit

Either the entrance or exit sensor detectspaper just after the unit is initialized.

Non-feed at the entranceEntrance

The entrance sensor is not activated within acertain period after the paper exit sensordetects paper.

Jamming at the entranceEntrance

The entrance sensor is not de-activated afterpaper is fed 1.3 times the length of thepaper.

Non-feed inside the unit(Straight feed out mode only) Exit

The exit sensor is not activated within acertain period after the entrance sensordetects paper.

Jamming at the exit Exit The exit sensor is not de-activated afterpaper is fed for a certain period.

Jogger tray Exit The exit sensor is de-activated during papershifting or stapling.

2.2.4 ERROR DETECTIONConditions

Jogger motor error Jogger home position sensor does not shut off after joggermotor starts.

Jogger motor home positiondetection error

Jogger home position sensor does not turn on after papershifting.

Stapler error Stapler home position sensor (inside stapler unit) does notturn on after stapling.

Output tray upper limit error Tray upper limit sensor is activated.Output tray motor error The output tray is away from the target position for more

than 10 seconds.Stack height detection error The stack height detection lever does not return to its home

position before going to detect the stack height.

NOTE: The above errors are indicated as “Finisher jam” at the first occurrence.If the same error happens again in the next job, “finisher error” is indicated.

10 August, 2001 SPECIFICATIONS

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3. OVERALL MACHINE INFORMATION3.1 SPECIFICATIONSPaper Size: A3, B4, A4, B5 sideways (Metric)

DLT, LG, LT (Inch)Paper Weight 52 ~ 128 g/m2, 14 ~ 34 lb.Staple Capacity: 20 sheets (A3, B4, DLT, LG : 80 g/m2, 20 lb)

30 sheets (A4, B5 sideways, LT : 80 g/m2, 20 lb)Stack Capacity (Maximum): 500 sheets (A4/LT or smaller: 80 g/m2, 20 lb.)

250 sheets (A3, B4, DLT and LG: 80 g/m2, 20 lb.)

Stapling Positions: 1Staple Replenishment: Cartridge (3,000 staples/cartridge)Power Source: 24 V DC, 5 V DC (from the copier/printer)Power Consumption: 48 WWeight: 8.3 kg (18.4 lbs.)Dimensions (W x D x H): 350 x 490 x 230 mm

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